service repair manual

1. REPAIR MANUAL
NEW HOLLAND
CS520
CS540
CS640
CS660
CL560

2. REPAIR MANUAL
CL560
CS520
CS540
CS640
CS660
604_34_011_00 5 27/05/2005

3. Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
POWER TRAIN C
TRAVELLING D
BODY AND STRUCTURE E
FRAME POSITIONING F
TOOL POSITIONING G
CROP PROCESSING K
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4. INTRODUCTION
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1

5. INTRODUCTION
Foreword ( - A.10.A.40)
CS540, CS640, CS520, CS660, CL560
Technical Information
This manual has been produced by a new technical information system. This new system is designed to deliver
technical information electronically through CDROM and in paper manuals. A coding system called ICE has been
developed to link the technical information to other Product Support functions e.g. Warranty.
Technical information is written to support the maintenance and service of the functions or systems on a customers
machine. When a customer has a concern on his machine it is usually because a function or system on his machine
is not working at all, is not working efficiently, or is not responding correctly to his commands. When you refer to the
technical information in this manual to resolve that customers concern, you will find all the information classified
using the new ICE coding, according to the functions or systems on that machine. Once you have located the
technical information for that function or system then you will find all the mechanical, electrical or hydraulic devices,
components, assemblies and sub assemblies for that function or system. You will also find all the types of information
that have been written for that function or system, the technical data (specifications), the functional data (how it
works), the diagnostic data (fault codes and troubleshooting) and the service data (remove, install adjust, etc.).
By integrating this new ICE coding into technical information , you will be able to search and retrieve just the right
piece of technical information you need to resolve that customers concern on his machine. This is made possible by
attaching 3 categories to each piece of technical information during the authoring process.
The first category is the Location, the second category is the Information Type and the third category is the Product:
• LOCATION - is the component or function on the machine, that the piece of technical information is going to
describe e.g. Fuel tank.
• INFORMATION TYPE - is the piece of technical information that has been written for a particular component or
function on the machine e.g. Capacity would be a type of Technical Data that would describe the amount
of fuel held by the Fuel tank.
• PRODUCT - is the model that the piece of technical information is written for.
Every piece of technical information will have those 3 categories attached to it. You will be able to use any
combination of those categories to find the right piece of technical information you need to resolve that customers
concern on his machine.
That information could be:
• the description of how to remove the cylinder head
• a table of specifications for a hydraulic pump
• a fault code
• a troubleshooting table
• a special tool
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6. INTRODUCTION
How to Use this Manual
This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at
the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included
at the end of a Chapter. Page number references are included for every piece of technical information listed in
the Chapter Contents or Chapter Index.
Each Chapter is divided into four Information types:
• Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components and,
assemblies.
• Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components and
assemblies.
• Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or
hydraulic devices, components and assemblies.
• Service data (remove disassembly, assemble, install) for all the mechanical, electrical or hydraulic devices,
components and assemblies.
Sections
Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by
a letter A, B, C etc. The amount of Sections included in the manual will depend on the type and function of the
machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This
table illustrates which Sections could be included in a manual for a particular product.
SECTION
A - Distribution Systems
B - Power Production
C - Power Train
D - Travelling
E - Body and Structure
F - Frame Positioning
G - Tool Positioning
H - Working Arm
J - Tools and Couplers
K - Crop Processing
L - Field Processing
PRODUCT
Tractors X X X X X X X X
Vehicles with working arms: backhoes,
excavators, skid steers, .....
X X X X X X X X X
Combines, forage harvesters, balers, .... X X X X X X X X X X
Seeding, planting, floating, spraying
equipment, ....
X X X X X X X X X
Mounted equipment and tools, ..... X X X X
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7. INTRODUCTION
This manual contains these Sections. The contents of each Section are explained over the following pages.
Contents
INTRODUCTION
DISTRIBUTION SYSTEMS A
POWER PRODUCTION B
POWER TRAIN C
TRAVELLING D
BODY AND STRUCTURE E
TOOL POSITIONING G
CROP PROCESSING K
Section Contents
SECTION A, DISTRIBUTION SYSTEMS
This Section covers the main systems that interact with most of the functions of the product. It includes the central
parts of the hydraulic, electrical, electronic, pneumatic, lighting and grease lubrication systems. The components
that are dedicated to a specific function are listed in the Chapter where all the technical information for that function
is included.
SECTION B, POWER PRODUCTION
This Section covers all the functions related to the production of power to move the machine and to drive various
devices.
SECTION C, POWER TRAIN
This Section covers all the functions related to the transmission of power from the engine to the axles and to internal
or external devices and additional Process Drive functions.
SECTION D, TRAVELLING
This Section covers all the functions related to moving the machine, including tracks, wheels, steering and braking.
It covers all the axles both driven axles and non-driven axles, including any axle suspension.
SECTION E, BODY AND STRUCTURE
This Section covers all the main functions and systems related to the structure and body of the machine. Including
the frame, the shields, the operator’s cab and the platform.
SECTION G, TOOL POSITIONING
This Section covers all the functions related to the final and/or automatic positioning of the tool once the tool is
positioned using the Working Arm or the machine frame.
SECTION K, CROP PROCESSING
This Section covers all the functions related to crop processing.
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8. INTRODUCTION
Chapters
Each Chapter is identified by a letter and number combination e.g. Engine B.10.A The first letter is identical to the
Section letter i.e. Chapter B.10 is inside Section B, Power Production.
CONTENTS
The Chapter Contents lists all the technical data (specifications), functional data (how it works), service data
(remove, install adjust, etc..) and diagnostic data (fault codes and troubleshooting) that have been written in that
Chapter for that function or system on the machine.
Contents
POWER PRODUCTION
ENGINE _ 10.A
TECHNICAL DATA
ENGINE - General specification (B.10.A - D.40.A.10)
CS540
FUNCTIONAL DATA
ENGINE - Dynamic description (B.10.A - C.30.A.10)
CS540
SERVICE
ENGINE - Remove (B.10.A - F.10.A.10)
CS540
DIAGNOSTIC
ENGINE - Troubleshooting (B.10.A - G.40.A.10)
CS540
INDEX
The Chapter Index lists in alphabetical order all the types of information (called Information Units) that have been
written in that Chapter for that function or system on the machine.
Index
POWER PRODUCTION - B
ENGINE
ENGINE - Dynamic description (B.10.A - C.30.A.10)
CS540
ENGINE - General specification (B.10.A - D.40.A.10)
CS540
ENGINE - Remove (B.10.A - F.10.A.10)
CS540
ENGINE - Troubleshooting (B.10.A - G.40.A.10)
CS540
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9. INTRODUCTION
Information Units and Information Search
Each chapter is composed of information units. Each information unit has the ICE code shown in parentheses which
indicates the function and the type of information written in that information unit. Each information unit has a page
reference within that Chapter. The information units provide a quick and easy way to find just the right piece of
technical information you are looking for.
example information unit Stack valve - Sectional View (A.10.A.18 - C.10.A.30)
Information Unit ICE code A 10.A 18 C 10.A.30
ICE code classification Distribution
systems
Primary
hydraulic
power
Stack valve Functional
data
Sectional view
CRIL03J033E01 1
Navigate to the correct information unit you are searching for by identifying the function and information type
from the ICE code.
• (1) Function and (2) Information type.
• (A) corresponds to the sections of the repair manual.
(B) corresponds to the chapters of the repair manual.
(C) corresponds to the type of information listed in the chapter contents, Technical data, Functional Data,
Diagnostic or Service.
(A) and (B) are also shown in the page numbering on the page footer.
THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL.
• You will find a table of contents at the beginning and end of each section and chapter.
You will find an alphabetical index at the end of each chapter.
• By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly
find the information you are looking for.
Page Header and Footer
The page header will contain the following references:
• Section and Chapter description
The page footer will contain the following references:
• Publication number for that Manual, Section or Chapter.
• Version reference for that publication.
• Publication date
• Section, chapter and page reference e.g. A.10.A / 9
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10. REPAIR MANUAL
DISTRIBUTION SYSTEMS
CL560
CS520
CS540
CS640
CS660
45269 5 27/05/2005
A

11. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Component localisation
(A.10.A - C.40.B.20)
CS540, CS640, CS520, CS660, CL560
NOTE: To find the location of those components, refer to PRIMARY HYDRAULIC POWER SYSTEM - Overview
(A.10.A - C.40.B.10)
Header quick-release coupler (18) (or screw
couplers)
ZDA6003C 1
Steering valve (24)
ZDA7538A 2
Unload tube cylinder (14)
ZDA7539A 3
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12. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
From series 1320 to 1360:
Oil reservoir (5)
Filler cap with filter (6)
Breather with filter and non-return valve (33)
Low pressure filter (32)
ZDA7346F 4
From series 1364 onwards:
Oil reservoir (5)
Filler cap with filter (6)
Breather with filter and non-return valve (33)
Low pressure filter (32)
ZEIL04CS0100A0C 5
Load sensing valve (7)
Unloading tube control valve (13)
Reel vertical adjustment valve (15)
Reel horizontal adjustment valve (17)
Header and straw elevator reversing motor (21)
Accumulator (35)
ZEIL04CS0089A0B 6
Header height control valve (8)
High pressure relief valve (36)
ZEIL04CS0084A0B 7
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13. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Accumulator control valve (10)
Header suspension accumulator (11)
Pressure sensor (12)
ZDA7561A 8
Main hydraulic pump (2)
Pump (3) (Steering circuit)
Pump (4) (Lateral flotation)
High pressure relief valve (26)
ZDA7560A 9
Drain hose (31)
ZDA5943E 10
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14. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
PRIMARY HYDRAULIC POWER SYSTEM - Component localisation
(A.10.A - C.40.B.20)
CS540, CS640, CS520, CS660
NOTE: To find the location of those components, refer to PRIMARY HYDRAULIC POWER SYSTEM - Overview
(A.10.A - C.40.B.10)
Header lift cylinders (9)
ZDA5998C 1
Lateral float cylinder (29) (If lateral float installed)
ZDA7537A 2
(If hydraulic reverser)
Screw couplers with non return valve (22)
Header and straw elevator reversing motor (23)
ZDA6258B 3
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15. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Steering cylinder(s) (25)
ZDA7540A 4
Load sensing valve (27)
Lateral flotation control valve (28)
Lateral float minimum pressure valve (60 bar) (30)
Lateral float accumulator (120 bar) (30a)
Lateral float accumulator (85 bar) (30b)
ZDA6268B 5
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16. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Relief valve - Static description (A.10.A.16 - C.30.A.20)
CS540, CS640, CS520, CS660, CL560
The high pressure relief valve is situated above the hydraulic triple pump.
• The high pressure relief valve (26), set at 180 bar (2611 psi), protects the header height and main control
hydraulics.
• A relief valve incorporated in the main control valves has no function in our hydraulic system. Therefore, this
relief valve is set at 175 bar (2538 psi) to avoid interference.
ZDA7560B 1
ZDF0543A 2
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17. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Dynamic description (A.10.A.18 - C.30.A.10)
CS540, CS640, CS520, CS660, CL560
If all valves are in the "0" position, then:
The valves (13), (15), (17), (21) and (28), (Refer to Stack valve - Static description (A.10.A.18 - C.30.A.20)) are
closed, which means that the oil can not flow through these valves.
The pressure raises at (7b), (27b), until the load sensing spool is pushed open against spring pressure (delta P=3
bar) and the return pressure in the pilot line (7a), (27a). Now pump oil flows into the return line at standby pressure.
When activating one or more of the control spools, the hydraulic cylinder pressure (pump pressure measured after
the spool restriction) is present in the pilot line (7a), (27a) and closes the load sensing spool. The pressure oil is
available for the activated control spool(s).
When the pump pressure reaches the cylinder pressure (+3 bar), the load sensing spool is pushed partially open.
The necessary amount of oil will flow to the control spool at the needed pressure. Excess oil is dumped into the
return line.
ZDA6268B_55 1
When the cylinder reaches end of stroke, the system pressure starts to raise. When the pilot pressure reaches 207
bar for the main stack valve (175 bar for the lateral float stack valve) the pressure relief valve is pushed open and
system pressure is limited to 210 bar (207 + 3 bar)The load sensing lockout valves, (13a), (15a), (17a), (21a), (28a)
between the different control spools make sure that pilot pressure cannot escape into the return over not used control
spools. When using more then one control spool the highest pilot pressure will operate the load sensing spool.
ZEIL04CS0089A0B 2
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18. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
ZEIL04CS0097F0B 3
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19. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
The load sensing lockout valves, (13a), (15a), (17a), (21a), (28a) between the different control spools make sure
that pilot pressure can not escape into the return over not used control spools. When using more then one control
spool the highest pilot pressure will operate the load sensing spool.
ZEIL04CS0098A0B 4
Function of lockout valves in the connections towards the cylinders.
When standby oil enters area (2a), ball (5) and valve (6) will be moved against the pressure in area (1a) and
spring tension (7).
Now standby oil is allowed to enter area (1a) through housing (4) towards the hydraulic cylinder (1).
The other side of the cylinder is connected to the lockout valve on the other side of connecting piece (2). This
lockout valve is still closed, so pressure will build up until connecting piece (2) moves to the right and opens the
right-hand side lockout valve, allowing the oil to enter the return line.
For some applications, the valve housing (4) is completely blocked by shims (1). This is to make sure that the
passage between area (1a) and (2a) is blocked. In that case the full oil flow will have to pass through valve housing
(4) instead of moving the complete valve housing.
ZDF0489A 5
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20. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Operation of reversing system valve (21).
In neutral position of the valve, both motor connections are connected to each other by the returns system. The
load sensing line is also connected to the return system. When switching the valve to position “1" or “2", lockout
valve (21a) (Refer to Stack valve - Static description (A.10.A.18 - C.30.A.20)) allows standby oil to flow into the
load sensing line. Now full oil flow is available towards the hydraulic motor.
ZEIL04CS0089A0B 6
Load sensing lockout valve (21a)
ZEIL04CS0098A0B 7
ZDF0488A 8
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21. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Operation of the reel vertical adjustment valve (15).
When switching one of these valves, load sensing lockout valve (15a) (Refer to Stack valve - Static description
(A.10.A.18 - C.30.A.20)) allows standby oil to enter the load sensing line. Now full oil flow is available towards the
hydraulic cylinder.These valves are connected to a single-acting cylinder which means that only one lockout valve
(fig.5) is provided in the connection towards the cylinder.
ZEIL04CS0089A0B 9
Load sensing lockout valve (15a)
ZEIL04CS0098A0B 10
ZEIL04CS0099F0B 11
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22. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Operation of the unloading tube control valve (13), the reel horizontal adjustment valve (17) and the lateral float
control valve (28).
When switching one of these valves, lockout valves (13a), (17a) or (28a) allow standby oil to enter the load
sensing line.
Now full oil flow is available towards the hydraulic cylinder. Lockout valves are installed in the connections towards
the cylinder. (see fig.5)
ZEIL04CS0089A0B 12
ZDA6268B_55 13
ZDF0485A 14
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23. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Static description (A.10.A.18 - C.30.A.20)
CS540, CS640, CS520, CS660, CL560
The main hydraulic system will be a open centre load sensing system that controls all high pressure functions: All
header functions and unloading auger swing.
The hydraulic system on CS combines contains two stack valves:
• Main stack valve (1). (see also hydraulic schematic below) Located at the left-hand side of the cab behind the
steering platform.
ZEIL04CS0089A0B 1
• Lateral float stack valve (2). (see also hydraulic schematic below) Located at the left-hand side of the straw
elevator.
ZDA6268B_55 2
• Header height control valve (3). (see also hydraulic schematic below) Located at the engine compartment.
ZEIL04CS0084A0B 3
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24. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
ZEIL04CS0007H0C 4
The stack valves (1) and (2) consists of two main parts.
• Control valves for oil supply and load sensing (7 and 27)
Refer to PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20)
Load sensing is a system which avoids high pressure when the valves are in neutral position and consequently,
less heating up of the oil and creating load-independent flow rate control.
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25. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
ZDA6268B_55 5
• Control valves with load sensing (13-15-17-21-28)
Refer to PRIMARY HYDRAULIC POWER SYSTEM - Hydraulic schema (A.10.A - C.20.B.20)
ZEIL04CS0089A0B 6
13 Unloading tube movement
15 Reel vertical adjustment
17 Reel horizontal adjustment
21 Reversing system
28 Lateral float system
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26. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Hydraulic pump - Exploded view (A.10.A.20 - C.10.A.20)
CS540, CS640, CS520, CS660, CL560
ZDF0842A 1
Main hydraulic pump
1 Pump housing 2 Bearing end plate
3 Radial-lip-type oil seal 4 Retaining ring
5 Housing cover 6 Toothed washer
7 Toothed gear 8 Toothed gear
9 Woodruff key 10 Hexagon nut
11 Spring lock washer 12 Protective cap
13 Protective cap 14 Bushing
15 Bushing 16 Head screw
17 Straight pin 18 Straight pin
19 Set of seals
NOTE: Tighten the screw (16) with a torque between 12 - 16 Nm. (9 - 12 lb ft)
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28. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Oil filter - Static description (A.10.A.24 - C.30.A.20)
CS540, CS640, CS520, CS660, CL560
The low pressure filter (32) is installed on top of the hydraulic reservoir (5) and has a bypass (non-return) valve
set to 1.15 bar (17 psi).The return oil from the hydraulics system is flowing through the low pressure filter before
entering the hydraulic oil reservoir.
ZDA7346F_58 1
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29. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Breather - Static description (A.10.A.26 - C.30.A.20)
CS540, CS640, CS520, CS660, CL560
The breather (33) allows the air in the reservoir to escape whenever a considerable oil flow arrives at the reservoir
(e.g. when lowering the attachment).
ZDA7346F_58 1
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30. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Remove (A.10.A.18 - F.10.A.10)
CS540, CS640, CS520, CS660, CL560
1. Start the engine.
2. Ensure that the machine component involved (e.g.
reel, header, ...) is completely down (cylinder fully
retracted) to release any possible pressure on the
valves.
3. Stop the engine.
IMPORTANT: Be sure that the area around the stack
valves is clean before removing them. Dirt contamination
will cause hydraulic component damage and/or failure.
Use caution while washing to keep electrical components
as dry as possible.
4. Drain the hydraulic oil from the reservoir trough the
drain hose and catch the oil into a clean suitable
container. (Refer to the CS Operator’s Manual:
"Section 4 - Lubrication and Maintenance")
5. Disconnect all the electrical connectors (1) from the
valve solenoids.
NOTE: Mark all electrical connector locations for proper
connection during assembly.
ZDA7884A 1
6. Loosen and disconnect the hydraulic line fittings (2)
from the stack valve. Cap and plug all lines and
fittings.
NOTE: When disconnecting the hydraulic lines, have a
suitable container readily available to capture any residual
hydraulic oil.
IMPORTANT: Lines and fittings must be capped and
plugged when disconnected to avoid contamination. Dirt
contamination will cause hydraulic component damage
and/or failure.
ZDF0480A 2
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31. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
7. Loosen the two bolts (3) at the bottom of the support
of the stack valve.
ZDF0738A 3
8. Loosen the two bolts (4) at the top of the support
of the stack valve.
Now is it possible to remove the stack valve with
the support.
ZDF0737A 4
9. Loosen the bolts to remove the support (5) from the
main stack valve.
ZEIL04CS0090A0B 5
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32. DISTRIBUTION SYSTEMS - PRIMARY HYDRAULIC POWER SYSTEM
Stack valve - Install (A.10.A.18 - F.10.A.15)
CS540, CS640, CS520, CS660, CL560
1. Bring the stack valve with the support (5) installed
in place.
ZEIL04CS0090A0B 1
2. Install the two bolts (4) at the top of the support.
ZDF0737A_61 2
3. Install the two bolts (3) at the bottom of the support.
ZDF0738A 3
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